Vertical Servo Hot Plate Welder

The VS-1445 is a vertical heat platen orientation, servo-electric motion controlled hot plate welding system capable of unparalleled control and ultra-precise welding of parts up to 14" x 45" (356mm x 1143mm) or multiple smaller parts. Customized variants of this model are available.

The vertical servo system's twin motion (left and right) tool mounting jaws allow independent control of collapse/absolute distance, time, force & speed on each part half, both when against heat platen in melt phase and against each other in weld phase. Typical hard-stops found in use on most systems are eliminated.

When compared to horizontal platen systems, vertical systems typically:

  • Allow faster tooling changeovers.
  • Allow easier and more positive operator loading and unloading of the tooling.
  • Ensure more precise part half alignment during welding (less scrap) as no special part-part alignment features must be designed into the parts themselves (required for accurate machine pick-up of one part half on horizontal systems).

Optional Features.

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Standard Features

Ultra-Rigid Stopless Construction utilizing a tubular steel framework and linear guide shafts & bearings with a Rack/Pinion alignment mechanism designed for extremely precise tool repeatability without measurable deflection through decades of use. The heat platen carriage assembly is completely rigid and is thermally isolated from the heat platens themselves. Rigidity of heat platen carriage construction allows system to perform precise melt of one part half only at full force against heat platen without deflecting the assembly.

100% Servo-Electric Motion Control enables unsurpassed weld repeatability, improved process control, and optimal motion control by allowing user to program precise tool mounting jaw positions, speeds, and forces without need for mechanical hardstops within the tooling. Advantages:

  • Melt & Weld (Seal) steps by Time, Collapse, or Absolute Distance (in 0.001 inch increments).
  • Faster Transition Times (from Melt to Weld Steps) for stronger bonds.
  • Allows Programming of Individual Melt Duration (set by Time, Collapse, or Absolute Distance) of one part half prior to the other. Typically used when welding dissimilar materials.
  • Soft-Touch Contact of Part Halves to heat platen (Melt) and each other (Weld/Seal) increases Teflon cloth/coating life.
  • Pre-Melt Joint Softening Control further increases Teflon cloth/coating life by allowing positioning of parts to within approximately 0.005 inches of the heat platen and then stops for a programmable time to achieve softening of the joint prior to contact with the Teflon cloth/coating on the heat platen.

Digital Four-Zone Temperature Control via PLC with Heater Burnout Alarm ensures even heating and precise temperature control with temperature alarm limits. Burnout alarm halts operation of the machine in the event of platen heater failure.

Programmable Automatic Heat Platen Startup (Time/Date Based) saves production time as the machine can be user programmed to automatically initialize warm-up of heat platen before start of production.

Allen Bradley CompactLogix PLC with PanelView Plus 7 - 1000 Color 10.4in Touch-Screen Graphical Display simplifies parameter input and allows the following to be displayed:

  • Individual Tool Mounting Jaw Melt & Weld (Seal), Collapse/Absolute Distance, Time, Force, & Speed Settings
  • Heat Platen Assembly Position & Speed Settings
  • Melt Offset Parameters (melt of one part half prior to the other) for Dissimilar Materials
  • Process Verfication (Pass/Fail) Windows on: Melt & Seal Time, Collapse Distance, Absolute Distance; Open Time
  • Digital Temperature Control Settings and Alarm Limits
  • Detailed Help Menus

Pendant Arm Mounted User Interface allows easy repositioning of interface panel to optimal location based on preference of user.

Multi-Level Passcode Protection limits parameter adjustment to qualified personnel only.

25 Weld Program/Setup Memory allows storage for instant recall, minimizing tool change time.

External Ethernet Communication Port and 120VAC Outlet allows bi-directional communication for interfacing between customer computer and PLC as well as detailed data output. Single 120VAC outlet allows user to easily connect small auxiliary such as computers, printers, radios, etc.

Dual Venturi 25.0 in/Hg (63.5cm/Hg) Vacuum Pump System designed to secure even the largest parts within the tooling.

Pneumatic Power Sliding Safety Door with Zero Force Cycle Activation Switch and Door Safety Tapeswitch provides optimum personnel protection while reducing operator fatigue.

Sequence of Operation

  • 1.Operator loads part halves into holding fixtures.
  • 2.Operator initiates cycle activation switch.
  • 3.Safety door closes.
  • 4.Part halves are automatically held with vacuum or mechanical grippers.
  • 5.Heat platen advances between part halves.
  • 6.Holding fixtures apply part halves to heat platen.
  • 7.Holding fixtures retract from heat platen.
  • 8.Heat platen retracts.
  • 9.Holding fixtures apply part halves together, welding parts together.
  • 10.One holding fixture releases its clamping mechanism.
  • 11.Holding fixtures retract, retaining welded part(s) in one fixture.
  • 12.Safety door opens.
  • 13.Operator unloads welded part(s).